Quality Control

 Quality Control and Quality Assurance are two of the main advantages to the FALCON Brewing System.  The on-site brewer need only be concerned with taking a few simple measurements of the product.  The rest is done for him.           

Because we custom blend every batch of ingredients to match the specifics of the recipe, we are able to take things like potential extract of a particular batch of malt and the diastatic power of a particular lot of high dried malt into consideration while blending the “pillows” for a particular recipe. 

As far as QC/QA of those raw materials are concerned, we use the lot analysis for raw materials supplied by the maltser as well as spot checking those analysis for accuracy using a few simple ASBC (American Society of Brewing Chemists) and MBAA (Master Brewer’s Association of the Americas) methods. 

All of our yeast storage, handling, propagation and testing is done in-house.  We store our yeast cultures using the sterile liquor method as well as keeping the culture pure on slants and plates.   

When one of our client breweries orders the raw materials for a batch of beer, whether it be a proprietary recipe or one of our core products, we grow a hyper-concentrated yeast slurry that will deliver a perfect cell count to the wort.  These cultures are tested and re-tested for purity with selective media and visual inspection through a microscope. 

The belief that the brewing process requires manual on-the-spot consideration at all times is a product of the small-scale brewing industry’s approach to the process.  The two largest brewing concerns in the United States produce very consistent product on a very large scale at multiple locations.  To achieve this they employ the same level of automation that we are applying to much smaller equipment.  This automation can be taken to any level.   There is one very large brewery in Colorado in which brewers routinely begin the brew via a dial-up connection before they even take a shower in the morning.  This level of automation is applied to every conceivable manufacturing process from automobiles to doughnuts and brewing is not much different in this regard. 

We do not approach the process, however, with the attitude that nothing can go wrong.  Equipment problems can and do arise.  When these issues arise, our brewery clients are instructed on what to do to handle the situation – shutting down the process to insure their safety and the safety of the equipment.  Each valve and every process is clearly labeled and, because we have not only designed the equipment but also are the authors of their particular process, we can assess the problem over the telephone and prescribe a remedy.  Whether the brewery is in need of a lengthy explanation of how to go about manually completing the brew (which would be the rarest and most extreme of cases) or needs to be shipped a replacement part (gasket, seal, hose) we are available continuously via cellular telephone and email.

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